Abstract: A direct reduction system and process for reducing a metal oxide to a metal, including and utilizing: a process gas line configured to deliver a portion of a process gas to a reformer operable for reforming the process gas to form a reformed gas; a bustle gas line configured to deliver the reformed gas to a shaft furnace as a bustle gas, wherein the shaft furnace is operable for reducing the metal oxide to the metal; and a direct recycle line including a direct recycle cooler configured to selectively deliver a portion of the process gas to the bustle gas line while circumventing the reformer, thereby selectively cooling and lowering the moisture content of the bustle gas delivered to the shaft furnace. Optionally, the direct reduction system further includes a reheat line configured to deliver a portion of the bustle gas to the shaft furnace as reheat gas.

Abstract: The invention relates to a plant complex for steel production comprising a blast furnace for producing pig iron, a converter steel mill for producing crude steel, a gas-conducting system for gases that occur when producing the pig iron and/or the crude steel, and a power-generating plant for electricity generation. The power-generating plant is designed as a gas-turbine power-generating plant or gas-turbine and steam-turbine power-generating plant and is operated with a gas that comprises at least a partial amount of the blast-furnace top gas that occurs in the blast furnace and/or a partial amount of the converter gas. The plant complex additionally comprises a chemical plant and a biotechnological plant, the power-generating plant, the chemical plant and the biotechnological plant being arranged in a parallel setup with regard to the gas supply. The gas-conducting system comprises an operationally controllable gas-distributing device for dividing the streams of gas.

Abstract: A method and a plant for the production of pig iron or liquid steel semi-finished products are shown, metal oxide-containing batch materials and, if appropriate, aggregates being at least partially reduced in a reduction zone by a reduction gas, subsequently being introduced into a smelting zone and being smelted along with the supply of carbon carriers and oxygen-containing gas and along with the formation of the reduction gas. The reduction gas formed in the smelting zone is supplied to the reduction zone, reacted there and drawn off as export gas, CO2 is separated from the export gas, and a product gas is formed which is utilized for the introduction of pulverulent carbon carriers into the smelting zone.

Abstract: The present invention relates to a method and apparatus for producing reduced iron from ironmaking dust which contains iron oxide which is generated at an ironmaking plant, takes note of the rotary kiln reduction method which does not require pretreatment of the dust, and has as its problem the pursuit of facilities which achieve further improvement of heat efficiency and stable operation. To solve this problem, the present invention is characterized by heating and reducing carbon-containing shaped materials in a single closed space in which an internal heat type rotary kiln and an external heat type rotary kiln are arranged in series and including at least the insides of the two rotary kilns during which making the reduced exhaust gas which is generated at the external heat type rotary kiln burn inside of the internal heat type rotary kiln.

Abstract: The present invention provides a valuable metal recovery apparatus capable of discharging clean exhaust gas. The apparatus 1 includes a furnace body 2; a heating container 3; a first combustion burner 10 for supplying heated gas into the furnace body 2; a tower 4 projecting upward from the furnace body 2; a gas combustion chamber 5 communicating with the tower 4 and being used for receiving unburned gas generated upon heating of a material to be treated; a second combustion burner 11 for supplying heated gas into the gas combustion chamber 5; a gas introducing passage 7 for introducing combustion gas generated in the gas combustion chamber 5 into the furnace body 2; a flue 21 for discharging the combustion gas in the furnace body 2 to the outside; and a support 8 supporting the furnace body 2 such that the furnace body 2 can be tilted.

Abstract: The present invention concerns a method and an apparatus for producing DRI (Direct Reduced Iron) utilizing a high-oxidation reducing gas containing carbon monoxide and hydrogen, derived directly or indirectly from the gasification of hydrocarbons or coal, with a high content of oxidants (H2O and CO2). The invention provides a more efficient method and plant comprising a reactor in which particulate material of iron ore comes into contact with a high temperature reducing gas to produce DRI, with lower investment and operating costs, avoiding the need for a fired heater for the reducing gas fed into the reduction reactor. The reducing gas is heated to a temperature above 700° C. in two steps, a first step at a temperature below about 400° C.

Abstract: A process for reducing iron oxide to metallic iron using coke oven gas (COG), including: a direct reduction shaft furnace for providing off gas; a COG source for injecting COG into a reducing gas stream including at least a portion of the off gas; and the direct reduction shaft furnace reducing iron oxide to metallic iron using the reducing gas stream and injected COG. The COG has a temperature of about 1,200 degrees C. or greater upon injection. The COG has a CH4 content of between about 2% and about 13%. Preferably, the COG is reformed COG. Optionally, the COG is fresh hot COG. The COG source includes a partial oxidation system. Optionally, the COG source includes a hot oxygen burner.

Abstract: A method and a plant for the production of pig iron or liquid steel semi-finished products are shown, metal oxide-containing batch materials and, if appropriate, aggregates being at least partially reduced in a reduction zone by a reduction gas, subsequently being introduced into a smelting zone and being smelted along with the supply of carbon carriers and oxygen-containing gas and along with the formation of the reduction gas. The reduction gas formed in the smelting zone is supplied to the reduction zone, reacted there and drawn off as export gas, CO2 is separated from the export gas, and a product gas is formed which is utilized for the introduction of pulverulent carbon carriers into the smelting zone.

Abstract: A heat treatment or heat soak furnace for use in both galvannealing and galvanizing processes including a heating apparatus configured to supply heat and remove heat. The heating apparatus may draw hot air from the exhaust of a direct fire strip annealing furnace, gas burners or electric heat exchangers as necessary. The furnace also may include a plurality of cooling mechanisms in order to ensure heat is removed and the temperature within the furnace regulated. In addition, the furnace may include baffles configured to allow portions of the interior of the furnace to be separated into different temperature zones.

Abstract: In certain exemplary embodiments, a system includes a gas turbine system having a turbine, combustor, and a compressor. The system also includes an output flow path from the gas turbine system. The system further includes a blast furnace coupled to the output flow path, wherein output flow path is configured to deliver heated air or exhaust gas from the gas turbine system directly to the blast furnace as a blast heat source.

Abstract: An apparatus for manufacturing fine particles includes a reactor; a first inlet part including at least one port introducing a reactive gas flow containing a fine particle source material; a second inlet part including at least one port introducing a diluting gas flow; a heater exciting the fine particle source material in the reactive gas flow; a first plate including through-holes which substantially equalize a flow rate of the reactive gas flow with respect to a cross section of a flow channel; a second plate including through-holes which substantially equalize a flow rate of the diluting gas flow with respect to a cross section of a flow channel; a gas exhaust port provided in a merging region where the reactive gas flow passed through the first plate and the diluting gas flow passed through the second plate are merged; and a collector which collects fine particles.

Abstract: The present invention relates to a combustion reactor for nanopowders, a synthesis apparatus for nanopowers using the combustion reactor, and a method of controlling the synthesis apparatus. The combustion reactor for nanopowders comprises an oxidized gas supply nozzle connected to an oxidized gas tube; a gas supply unit supplying a fuel gas and a precursor gas; and a reaction nozzle forming concentricity on an inner wall of the oxidized gas supply nozzle to be connected to the gas supply unit and having an inlet opening for supplying an oxidized gas disposed at a region adjacent to a jet orifice for spraying flames.

Abstract: A process for producing metallic ultra-fine powder, which can use a raw material which is spread over a wide range, and control freely the grain size of the metallic powder to be produced, at low cost and high safety. The process for producing the metallic ultra fine powder consists of using a burner and a furnace which can generate a high temperature reductive atmosphere, and an apparatus for separating gas which is generated in the furnace from powder to recover the powder. The burner has a function of blowing a powdery metallic compound as a raw material into a high temperature reductive flame. The raw material powder is efficiently heated in airflow of a high temperature reductive flame, thereby being reduced rapidly into metallic ultra-fine powder. At this time, the grain size of the metallic ultra-fine powder is controlled by adjusting the oxygen ratio (i.e.

Abstract: A method and apparatus for preheating a reactor feed, comprised of an iron ore (10) and a process gas (21), in an iron carbide process for making steel is provided. The apparatus comprises a process gas preheater (40) having a furnace (56) and a heat exchanger (58). The process gas (21) is heated uniformly in tubes (117) of furnace (56) by burners (100). Excess heat generated by furnace (56) is captured by heat exchanger (58) and used to preheat combustion air (61) and ore (10).

Abstract: A method and apparatus for the production of iron carbide in a shaft furnace, by reacting a carbon containing reducing gas as the process gas with particulate metal oxide material for an extended residence time at low temperature.

Abstract: An improved apparatus for reactor iron making has a furnace body to melt raw material, typically as scrap, a shaft to heat the raw material, and a raw material supply bucket, these three components being arranged vertically, with an exhaust gas combustion tower positioned close to the shaft.Raw material is supplied to the shaft with this apparatus by the bucket, and, after being heated by exhaust gas from the furnace body, the raw material is charged into the furnace body by the opening/closing operation of a shaft damper and a furnace body cover.Exhaust gas is introduced from the furnace body into the combination tower, air is supplied in stages, the temperature of the gas is gradually raised through combustion of CO, and the gas is used to heat the raw material in the shaft.

Abstract: A process for melting a ferrous burden comprising scrap iron, scrap steel, pig iron, direct reduced iron or mixtures thereof without the use of coke is provided. Air or enriched air as a primary oxidant is preheated and together with fuel is combusted to form a reducing atmosphere in a shaft furnace or forehearth which melts the ferrous burden in the melting zone of the shaft furnace. The reducing atmosphere leaving the melting zone of the shaft furnace is further combusted with a secondary oxidant in the preheating zone of the shaft furnace. The top gas from the preheating zone of the shaft furnace is combusted with a tertiary oxidant to provide a heated flue gas to preheat the primary oxidant. Optionally, the heat remaining in the flue gas after preheating the primary oxidant may be recovered in a waste heat recovery device.

Abstract: Metal bodies such as billets and blooms are reheated for rolling in a metal-refining operation having a blast furnace by first heating the top gas of the blast furnace to at least 800.degree. C. by means of a plasma torch, then, before the gas has cooled appreciably, burning the heated top gas in a preheating chamber. The metal bodies are exposed in the preheating chamber to the heat of the burning and heated top gas. The heated top gas is mixed with combustion-inducing gas to burn it. Before it is mixed with the heated top gas it is preheated by heat exchange with combustion-product gas withdrawn from the preheating chamber. In this manner it is possible to raise the temperature of this combustion-inducing gas to at least 600.degree. C., so that the burners firing the preheating chamber burn clean. In addition much of the heat of the process is recovered, again reducing energy costs for the system.

Abstract: A refractory lined melting furnace particularly suited for separation of non-ferrous metals with embedded or attached ferrous components, includes a casing or body pivotally mounted and tiltable by means of fluid operators. The interior is divided by two vertical walls into a combustible waste burning portion for the generation of combustible gases to assist in heating the furnace, and a melt chamber into which a variety of metallic waste can be charged for melting. A conventional fire burner is supplied to the melt chamber. The temperature of the melt chamber is raised to the melting point of the metallic waste material having the lowest melting point, e.g. aluminum, and when the aluminum is melted, the aluminum runs through drainage apertures into a liquid metal holding chamber provided on the floor of the melt chamber. When the molten metal has drained, the furnace is tilted rearwardly to discharge the remaining scrap out through rake-out doors at the rear of the melt chamber.

Abstract: Process and apparatus for the gaseous direct reduction of iron ores wherein at least a portion of the spent reducing gas effluent from a reduction reactor is upgraded and thereafter heated and recycled to said reactor forming a reducing gas loop and make-up reducing gas is added to said loop. The hot products of combustion, i.e., flue gases, in the reformer are used to heat the recycled gas (and optionally the quenched make-up gas) while maintaining independent control of the operating conditions of the reformer and gas heater to give improved thermal efficiency and fuel savings. The reformer has a stand-by stack through which the reformer flue gas is directed when the gas heater is shut down (to permit independent continuous operation of the reformer).

Abstract: A method for operating a blast furnace, characterized by: adding a prescribed volume of blast furnace gas to an air for blast fed to a hot stove; oxidizing, in the hot stove, CO contained in the blast furnace gas into CO.sub.2 and H.sub.2 contained therein into H.sub.2 O to prepare a blast containing CO.sub.2 and H.sub.2 O and additionally heated by the above-mentioned oxidation; blowing the resultant blast containing CO.sub.2 and H.sub.2 O into a blast furnace through tuyeres thereof; thereby controlling the calorific value at the portions around the tuyere exits as a result of the endothermic effect produced by the reactions at the portions around the tuyere exits of the CO.sub.2 and H.sub.2 O contained in the blast with red-hot coke in the blast furnace wherein the amount of the blast is substantially equal to that of a blast without addition of a blast furnace gas.

Abstract: Disclosed are a method and apparatus for manufacturing sponge iron by the continuous reduction of iron oxides in a shaft utilizing recirculation gases. Reaction gas is removed from the shaft furnace, substantially cleaned of all CO.sub.2 and H.sub.2 O, and then divided into at least two flow portions one of which is passed to a gas generator comprising a plasma burner. A reducing agent such as pit coal is injected together with an oxidant into the hot gas from the plasma burner so as to form a gas mixture comprised primarily of CO and H.sub.2, which gas mixture is then mixed with the other flow portion of the cleaned reaction gas in such proportion that the temperature of the resulting reduction gas is suitable for the reduction of iron oxides in the shaft furnace.

Abstract: Disclosed are a method and apparatus for manufacturing sponge iron by the continuous reduction of iron oxides in a shaft utilizing recirculation gases. Reaction gas is removed from the shaft furnace, substantially cleaned of all CO.sub.2 and H.sub.2 O, and then divided into at least two flow portions one of which is passed to a gas generator comprising a gas generating shaft substantially filled with a solid reducing agent and a plasma burner arranged in the lower portion of said shaft. An oxidant is injected into the hot gas from the plasma burner so as to form a gas mixture comprised primarily of CO and H.sub.2, which gas mixture is then mixed with the other flow portion of the cleaned reaction gas in such proportion that the temperature of the resulting reduction gas is suitable for the reduction of iron oxides in the shaft furnace.

Abstract: An apparatus is provided for regulating the percentage quantities of individual gases present in the combustion air supplied for reaction processes in metallurgy. A molecular sieve absorption material is used on the intake air to absorb the inert constituents to thereby enhance the quantity of oxygen present. The apparatus utilizes several molecular sieve materials in a continuous manner such that one of the devices containing the molecular sieve material is being purged for regeneration while another device is absorbing the inert constituents, while yet another device is cooling, i.e., getting ready for the absorption operation. The countercurrent flow of heated intake air, which air is derived from the metallurgical reaction process, is used in the apparatus for regenerating the molecular sieve material.

Abstract: The invention relates to an apparatus and a declogging process for filtration installation for dust-laden gases presenting reducing properties, consisting in taking dust-free gas at the outlet of the filtration installation, oxidizing this gas and using the gaseous mixture resulting from this oxidization to declog the filtering element(s) of said installation.

Abstract: A method and apparatus for preparing a hot reducing gas for introduction into a vessel containing ore oxide in order to react with the ore oxide to produce reduced metal including the steps of combusting a fuel with no more than a stoichiometric amount of air to produce a heating gas having an absence of available oxygen, mixing the heating gas with an initially preheated reducing gas stream in order to heat the initially preheated reducing gas stream without spending any of the reducing strength thereof and further to mixing such air and fuel to produce a heating gas which will cause the formation of additional reducing constituents.

Abstract: Iron ore pellets on a grid in a treatment chamber are hardened by contact with a heat treated, low calorific gas. The gas is generated in the gasification chamber of a slag bath generator. The generator receives a gasification agent and solid fuel that preferably further includes sulfur-binding materials, such as dolomite for generating a stream of low calorific gas. Inclined water-cooled pipes at the upper end of the slag bath generator extract liquid slag from the gas stream. The slag drips from the pipes into the slag bath generator. A mixing chamber receives the gas at a temperature of about 1450.degree. C passed beyond the inclined water-cooled pipes together with an air supply for heat treating the gas to a temperature of about 1100.degree. C. The heat treated gas is then passed into the treatment chamber for hardening the iron ore pellets contained therein.